Ok Projrct

PROJECT REPORT 2021-2022
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KIADB INDUSTRAIAL ARE

KUMDUMALKUNTE GOWRIBIDANUR -
561208
PROJECT REPORT
Done at
YG-1 CUTTING TOOLS
KIADB IND.AREA,PHASE 3,IBADENAHALLI
DODDBALLPURABANGALORE-562103
MANUFACTURING OF CUTTING TOOLS
SUBMITTED BY : RAKESH V R
REG NO : 1260231
BATCH : 02
PERIOD : 2021-202
GOVT. TOOL ROOM & TRAINING CENTRE

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KIADB INDUSTRAIAL ARE

KUMDUMALKUNTE GOWRIBIDANUR -
561208
(A Scientific & Industrial Research Organization Recognized by Government of India)
PROJECT REPORT ON
CUTTING TOOLS
SUBMITTED BY
RAKESH V R
NAME:
BATCH:
YG CUTTIN TOOLS -1 INDIA Pvt Ltd .

KIADB INDUSTRIAL AREA
DODDBALLPURA
BANGALORE-56203
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KIADB INDUSTRIAL ARES

KUDUMALKUNTE
GOWRIBIDANUR -561208
CERTIFICATE
This to certify that Mr RAKESH V R Reg.No.1260231 of IInd BATCH

has successfully completed the project work on “CUTTING TOOLS” in
fulfillment of the sessional requirements for the award of “DIPLOMA IN TOOL &
DIE MAKING ” From “ GOVT. TOOL ROOM & TRAINING CENTRE ”
Gauribidanur During the period of 2021-2022
VIVA
EXAMINER
PROJECT GUIDE PRINCIPAL

GT&TC GT&TC
GOWRIBIDANUR GOWRIBIDANUR
PLACE:
GOWRIBIDANUR
DATE:

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PROJECT REPORT EVALUATION
NAME : RAKESH BATCH :2

VR
REG NO:
1260231
EVALUATOR SIGNATURE:-
NAME :-
DATE :-
REMARKS :-

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AKNOWLEDGEMENT
First of all I will take great pleasure in expressing my deep sincere gratitude to
SRI, H. RAGHAVENDRA IRPS Managing Director GT&TC
Karnataka who has been guiding light to our organization.
I’m also greatfull to our Mr. THIPPESWAMY . C Manager/Unit Head

GT&TC Gauribidanur for giving me the opportunity to take our in plant
training, and subsequently preparing this project report.
I’m also indebted to our beloved Mr. HARISH KUMARN Principal GT&TC
Gauribidanur for giving me the privilege of completing my training. At this
estimated org.and also their assistance and support in course of this project.
At the same time I thank Ms. SONIYA S Placement Officer/IPT Incharge
and I thank MR. TIPPANA NAIK Project Guide and all the staff of GT&TC
for sharing their valuable experience and im-measurable Time. Their influence has
helped in moulding ourselves to a confident Tool Engineer . During the course of
this project I was greatly thankful to who all supported & guided by other staff
members of GTTC Gauribidanur , I will take this opportunity once again to thank
them all.
And my Sincere regards to all staff, employes, friends and well wishers of “ M/s
_______________________________ “ who directly or indirectly helped me
in carrying & completing my project successfully.
NAME: RAKESH V R
BATCH: 02
REG.NO:1260231

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Candidate’s Declaration
I am RAKESH V R student of DIPLOMA TOOL AND
DIE
MAKING bearing register number 1260231 hereby
conclusion provided in this project titled
“CUTTING TOOLS,,
Submitted to GOVT TOOL ROOM & TRAINING
CENTRE for the award of DIPLOMA TOOL AND DIE
MAKING 2020-21
To the best of my knowledge, the project
work has not been submitted in part or full
elsewhere in any other
institution/organization for the award of the
certificate of diploma/degree. I have
completely taken care in acknowledging
the contribution of others in the academic
work. I further declare that in case of any
violation of intellectual property rights and
particulars declared, found at any stage I,
as the candidate will be solemnly
responsible for the same
Signature of the candidate

Name: RAKESH V R
Register no.: 126023

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GT&TC AT A GLANCE
Government Tool Room and Training Centre (GTTC) was established in

1972 at Bengaluru with the participation from the State Government of Karnataka,
in collaboration with Government of Denmark under the Bilateral Development
Co-operation Agreement. A well-structured Diploma course on Mechatronics with
emphasis on “Hands-on” Training appears to be the need of automation Era. The
Objective of the course is to develop Multidisciplinary Engineers to cater the needs
of various industrial sectors like Automation & Robotics, Sensing & Control
Systems, Automotives and various Electrical & Electronics sectors .
Government Tool Room & Training Centre is one of the best institution in our
country imparting training &enhancing technological excellence in the field of
Engineering.
It offers key& package programs for tooling, product development &
component manufacturing facilities. It has also embarked upon research
&development of advanced tooling & machining techiniques & systems for various
R&D organization in india with a view of fostering self reliance & technological
upgradation.

GOWRIBIDANUR
INTRODUCTION TO
ORGANISATION.
GT&TC, GOWRIBIDANUR centre was started in 2017 to cater to the

needs of local industries. And to import training programme
in “DIPLOMA IN TOOL &DIE MAKING”. The duration is 1 years
training followed by one year compulsory industrial training.
Already GT&TC , GOWRIBIDANUR is serving many industries in &
around’ GOWRIBIDANUR with a set of modern general purpose machine
along with the CNC machine milling and wire EDM machines.
GT&TC is concentrating on the Integrated Development of the related
segments of industries by way of providing international quality tools,
trained personnel and consultancy in tooling and related areas. In future, the
focus would be more on turnkey projects in Tooling, Aerospace components
& their assemblies, and also to support the development of small and
medium scale enterprises.

GOWRIBIDANUR
Activities
Design & Manufacture of
Die Casting Dies
Plastic Moulds
Press Tools
Jigs and Fixtures
Plastic and Die-cast
Components
Research &
Development
Laser Technology
Centre
Heart Valve Cage
Tri-Cycle for Disabled
Patient Lift

GOWRIBIDANUR
Hi-Tech Components for

Defense
Aero-Space
Medical Applications
Research &
Development
Training - Long Term

Tool & Die Making
M. Tech in Tool
Engineering
Post-Dip. In Tool Design
(D)
Post-Dip. In Tool Design
(E)

GOWRIBIDANUR
Training - Short Term

CNC Machine Programming
Master Cam
Pro-Engineer
Auto-CAD
Computer Hardware
Assembly
Desk Top Publishing
Machines
CNC Machines
Jig Grinding / Boring, EDM and EDNC
etc
Coordinate Measuring Machine
New Frontiers
Applying Lean Manufacturing for Tool Engg. and
production
Providing MRP/ERP Implementation Support
GOWRIBIDANUR
Assignments
France, Bahrain, Malaysia
Technology Transfer: Malaysia and Turkmenistan
Consultancy Services Offered: Tool & Die Manufacture
Setting up Tool Rooms
Setting up Training Centers in courses mentioned.
Organization
Government Tool Room & Training Centre - dedicated to the cause of
imparting focused training and carrying out advanced fabrication activities
in the specified area of tools and dies- established in the year 1972 at
Bangalore, with the assistance of DANIDA, Denmark
GT&TC has extensive and State-of-Art facilities for research, development
and training to the complex tooling requirements of discerning customers
and also the quality human resource requirements of varieties of
manufacturing environments
GT&TC has an impressive array of both conventional and Hi
tech machining/fabricating facilities capable of addressing.

GOWRIBIDANUR
GT&TC AT THE GOVERNEMENT EFFECT

The Karnataka government, which has always projected an image of
strictness with regard to illegal educational institutions, is facing the fire
itself now.
The state-run engineering college, Government Tool Room And
Training Centre (GTTC), is in trouble. It had, for the academic
session of 2010-11, admitted 41 students to two cutting edges B.
Tech. courses, though it had apparently not received any approval for
the courses from the AICTE.

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TOWARDS
THE WORLD'S BEST
GLOBAL YG-1 GROUP
Founded in1982,YG-1YG-1 has grown to be a strong
and firm company recognized globally in the cutting
tool industry.

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"YG-1will keep develop ing further more innovative itams

and benefits as first priority.
We gratefully thank our clients for their generous
support .and wewe promise to move forward
with ,consistent passion.
,,

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YG-1 Mission, Vision & Core Value

Mr. Hoke Song Founded V-1 in 1982 and started with only 14 basic
conventional machines & 16 employs manufacturing End Mills. Now YS-1 is
one of the largest cuming tool companies that supplies to almost every
country in the world. Passion and Confidence are the key factors behind his
success
YG-1 MISSION, VISION & CORE VALUE
RELENTLESS
DRIVE ON THE
GLOBAL STAGE,
PERFECTING WITH THE
INNOVATION
YG-1 SPIRIT

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YG-1 STRATEGIES
YG-1, as a full range cutting tool supplier, is not only supplying but also
satisfying various industries around the world. From holding a full range of
cutting tools and maintaining a rigorous quality inspection level, YG-1 has
continuously gained trust for providing the highest quality products and
services to each customer.
YG-1, FULL RANGE CUTTING TOOL SUPPLIER

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MILESTONES
Jul 2000 Selected as the company with outstanding

1981-1999 | 2000-2005
competence
in quality (Ministry of Trade, Industry and
Dec.1981 Company founded Energyl Oct. 2000 Selected
Oct. 1982 Completionof Plant #1 in Incheon, Korea factory of Korea (KMA)
Feb. 1983 Export to US launched (End Mills) Jul 2001 Awarded with ISO 14001 certification (TÜV
Dec. 1985 Opening office in Chicago, US CERT) Oct. 2001 China branch founded (Qingdao New
Dec 1989 Selected as the company reachingWorld- Century
class Products [KOTRA) Tooll
Dec. 1991 Completion of Plant #2 in Incheon, Korea Nov. 2001Selected as INNO-BIZ Enterprise
May 1992 US branch founded (PCT) [Small & Medium Business Administration
Jun. 1993 Received permit for KS marks (Drills Certified as the world-leading quality product
Aug. 1995 Completion of Taps Plant in Ansan, Koera (Ministry of Trade, Industry and Energyl
Aug. 1996 Completion of Drills Plant in Gwangju, Certified as the Leading Company in export
Oct. 1996 uropa Tool established in UK korea of
Mar. 1997 Received EM Mark Certification partsmaterials
Apr. 1997 Germany branch founded < (Ministry of Trade, Industry and Energyl
Dec. 2000 converted to a corporation>from Apr. 2002 France branch founded (YG-1 Europe SASI
Government [Acquisition of a French company, Corai
Aug. 1997 Became public company (Registered in P&L
KOSDAQ market! SAS) Jul 2002 Ranked
Feb. 1998 Selected as one of the small/med-sized in top 50 companies with outstanding
export prospects (SBC) competence in product
Jul. 1999 Tool R&D Center founded in Incheon, quality (Ministry of Trade, Industry and
Korea Energy)
Aug. 1999 Ranked in top 50 companies with Sep. 2002 India branch founded (YG-1 Industries India
outstanding competencein Pvt.
Oct. 1999 Changed Corporate name to YG-1 Ltd.]
Nov.1999 Awarded First Grade Corporatein (Korea Jul. 2004 Construction of new headquarters in Incheon,
Testing Laboratory) Korea
Dec. 1999 Awarded with ISO 9001 certification (TÜV Mar. 2005 Awarded with ISO 9001/14001 certification
CERT) (DAS CERT)
Sep. 2005 Songdo R&D Center founded in Incheon, Korea

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R&D Center
Developing innovative cutting tools in order to create unique technologies of
YG-1. YG-I's technical departments are striving every day to lead the
cutting tool industry with the innovative The ultimate target of research and
development is our customers' needs.
SONGDO
R&D CENTER
The Songdo R&D Center is constantly developing new
technologies of YG-1 with the vision, Creative Thinking and
Innovation. It focuses on expansion in conversion research
through energetic inter-department communication. With the
constant innovation and accumulated experience, YG-1 has
become one of the biggest round tool suppliers and the No.1 End
Mill maker in the world.

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CHUNGJU
R&D CENTER
The Chungju R&D Center is equipped with high tech facilities to
produce new materials and products. It focuses on constantly
improving and upgrading YG-1's key technologies while working
in R&D and production. With its new insert plant and product
specialists, Chungju R&D Center will be the major part of YG-1's
growth going forward.

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Product Lines
MILLING
YG-1 milling tools are recognized as one of the most cost efficient
cutting tools in the world, satisfying many users by providing a
massive increases in prouctivity
YG-1is also well known for its outstanding performance and it's
wide variety of product, making it possible to cover avast range of
work materials and also numerous applications.

GOWRIBIDANUR
High Performance Products

High Precision Inserts with Steel & Carbide Holders for
Copy Milling
Optimized tool geometries applied for better reliability Several types of
inserts & holders obtained to cover various materials and applications
for mold & die industries
Blue Coated Nano Grain Solid Carbide X5070 End Mills for
High Hardened Steels (HRC50~70)
High speed machining, dry cutting, excellent tools for mold & die, also
for electric industry
Y-Coated Ultra Micro/Nano Grain Solid Carbide 4G Mill
End Mills for Pre-Hardened Steels (~HRc55)
High speed cutting, dry and wet cutting, excellent tools for mold & die
industry
Y-Coated Ultra Micro Grain Solid Carbide TitaNox Power

End Mills for Titanium, Stainless Steels
High speed machining for exotic materials
Excellent tools for aerospace industry, energy & power generation
Y-Coated Ultra Micro Grain Solid Carbide V7 Plus End
Mills for Steels, Cast Iron, Stainless Steels
Uniquely designed multiple helix with unequal indexing for maximum
performance / Heavy Cutting
Uncoated and DLC coated Micro Grain Solid Carbide End
Mills for Aluminum Machining
For High Speed Aluminum machining to reduce manufacturing cost
(Run up to 35,000rpm-2,0001PM)
Unique Substrate Carbide YG Mill Inserts for Milling

Application
Optimized Grades - High performance for mass production (G622, 712,
713, 613, 501, 5020, 50) Universal Grade - Ultra-dense PVD coating
with optimal thermal resistance & added strength for multi-
purpose(YG602)

GOWRIBIDANUR
HOLEMAKING
YG-1 Drilling tools are well known for its tight tolerance and high technology,
continuously impressing a manufacturers around the world -'s advanced
geometry brings out extraordinary performances, creating a longer tool life with
outstand
productivity, also a variety of sizes and shapes are available for diverse
applications

GOWRIBIDANUR
PRODUCT LINES
High Performance Exchangeable Drilling Tools for Carbon Steels,

Alloy Steels, Cast Iron
Micro grain carbide inserts and premium steel holders with secure
and quick clamping system
Z-Coated Solid Carbide Dream Drills Pro(with/without Coolant
Holes)for General Purpose (HRC 30-50)
Excellent Performance with Optimized Design and High Cutting
Speed Extremely high hardness and heat resistance
YG-1 Tailored TIAIN-Coated Solid Carbide Dream Drills General
(with/without Coolant Holes) for General Purpose (HRc30-50)
Special design for good centering, smooth chip removal and
powerful drilling
H-Coated Solid Carbide 3-Flutes Dream Drills High Feed (with
Coolant Holes) for Carbon Steels, Alloy Steels (~HRc35), Cast
Iron Increases productivity by 1.5-2 times faster in drilling
compared to 2-flute carbide drills
X-Coated Solid Carbide Dream Drills Flat Bottom (with/without
Coolant Holes) for Holes on Various Angled Surface
180 degree point angle enables drilling of horizontal surface,
sloped surface
Optimized flute shape for excellent chip evacuation
YG-1 Tailored TIAIN-Coated Solid Carbide Dream Drills INOX
(with/without Cod Holes) for Tough Materials like Stainless Steels,
Nickel Alloys and Titanium
Special flute shape and geometry for excellent chip removal Point
R-thinning makes a superior centering and chip curl
The Best Solution for Cost Effective and Productivity
3&4 corner economical insert with new PVD coating/Bigger chip
gullet for better chip evacuation

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THREADING
YG-1 Threading tools are highly acclaimed for its excellent quality and
unique design, constantly remaining Maintained by YG-1's tight quality
control, its unique geometry prevents over-feeding and also thin threading
problems, achieving a shorter cycle time and higher productivity

Solid Carbide Thread Mills for Multi-Purpose Applications
One tool for blind holes & through holes
Higher cutting speeds and feeds then tapping
Much higher productivity and improved thread surface finish
HSS-PM (Powder Metallurgy) Synchro Taps
for High Speed Tapping on Rigid CNC Machines
Suitable for high speed machining and high precision threads
Up to 3 times faster
X-Coated Prime Taps for CNC Machining on Various Ductile
Materials
Special grinding process provides an unique geometry on spiral fute and spiral
point p
to help control chip evacuation, preventing rest formation and enough flute
space

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TURNING
YG-1 Turning tools are the most cost effective cutting tools for various
machining applications and give lon tool life for increasing productivity. It
shows excellent cutting performance in general applications and also under
harsh machining conditions

Optimized and Universal Turning Grades with Various
YG TURN Chipbreakers
Optimized Grades-High performance for Mass production
(YG1001, 1010, 3010, 3015, 3020, 3030 211, 213, 214,401, 100,
Universal Grades - High versatility for Small quantity batch
production (Y6801)
Turning Tool for Small Bore Application

A wide range of insert series covering various application
Secure connection design ensures high repeatability for edge position
NanoCut

GOWRIBIDANUR
TOOLING SYSTEMS
YG-1 Tooling Systems offer an excellent clamping technology to meet all
specific demands for every kinds of machining applications. The systems
are optimally designed to run at high efficiency and productivity for
customers by providing a major increase in accuracy and repeatability.

GOWRIBIDANUR
GOWRIBIDANUR
We serve the volume Drills, Taps, End Mills, Spade Drills and Rotary
Tooling and are setting the pace and are known as the fastest growing
company in this industry. High worker productivity has allowed us to have
strong growth over the last 22 years, and our economies of scale allow us
competitive advantages. Only the highest quality materials and machinery
are used in the

GOWRIBIDANUR
YG-1 U.S.A. office and warehouse is located in Chicago, maintains a

large inventory and achieves a 98% fill rate. Our Chicago staff provides
courteous and efficient service. We provide easy to use, colorful, and
informative literature and prompt technical support. We have Field
Sales Staff covering United States. They will be pleased to speak with
you about your needs. Please click here to connect you to a Field Sales
Staff nearest you.

GOWRIBIDANUR
YG-1 Service Map

YG-1 products are being sold in over 75 countries. holding 28 sales office, 28
producton facilities worldwide, with 4,500 production machine and over
5,000 employees
TODAY YG-1, IS AMULUTNATIONAL COMPANY

GOWRIBIDANUR

GOWRIBIDANUR

GOWRIBIDANUR
Sales Network
BUSINESS SITES WORLDWIDE

GOWRIBIDANUR
Total Solution Provider, YG-1

YG-1 as a global leader in the manufacturing and application of cutting
tools, brings you these innovations worldwide
in the form of superior tooling, expert support and world class delivery

GOWRIBIDANUR

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WHY A PROJECT
A stuent undergoing technical course is expected to do some

experimentations and research work on the subject
he/she/studying.
The experimentation and research is needed as it helps in
gaining the practical aspects of the knowledge obtained in theory
classes. Technical student has to dedicate himself or herself in the
back breaking study that is needed in achievement of practical
knowledge so as to understand well, the theoretical part of study
encores. As it is better known A person with only theoretical
knowledge makes a good combination towards systematic
approach in attaining success, but a person with both theoretical
and practical knowledge makes success and achievement, a
bull’s-eye” .
Also gaining practical knowledge in any subject helps a
technical student in his / her academic career equips with
him/her later to perform a systematic and organized manner in
respective professional field. Project .Thus, why it is
necessary to so a
Every effect has been made to bring out a crystal clear
project in readers mind. Also in design, every possible care
has been taken to achieve accuracy, stability and durability.

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INTRODUCTION TO
CUTTING TOOLS

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What is End mill tool?

An end mill is a type of milling cutter, a cutting tool used in industrial milling
applications. It is distinguished from the drill bit in its application, geometry,
and manufacture. While a drill bit can only cut in the axial direction, most
milling bits can cut in the radial direction.
Not all mills can cut axially; those designed to cut axially are known as end mills.
End mills are used in milling applications such as profile milling, tracer milling,
face milling, and plunging.

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CUTTING TOOLS FOR TO END MILLS &

DRILLS
An end mill is a type of milling cutter, a cutting tool used in
industrial milling applications. It is distinguished from the drill bit
in its application, geometry, and manufacture. While a drill bit can
only cut in the axial direction, most milling bits can cut in the
radial direction. Not all mills can cut axially; those designed to cut
axially are known as end mills.
Several types of end mills
End mills are used in milling applications such as profile milling,
tracer milling, face milling, and plunging.
Several broad categories of end- and face-milling tools

exist, such as center-cutting versus non-center-cutting
(whether the mill can take plunging cuts); and
categorization by number of flutes; by helix angle; by
material; and by coating material. Each category may
be further divided by specific application and special
geometry.

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TYPES OF TOOL MANUFACTURING IN SOLID CARBIDE
1.Solid Carbide End Mills(EM)

a.Square EM(2FL & 4FL)
b.Ballnose EM(2FL & 4FL)
c.Corner radius EM(2FL & 4FL)
2.Solid Carbide Drills
a.Dream Drills
b.SS Drills
3.Specials Carbides
a. 1FL,2FL,3FL,4FL,5FL,6FL,8FL Square
b.2FL,3FL,4FL Ballnose EM
c.2FL,3FL,4FL,5FL,6FL&8FL Corner radiu
d. Hole MillS
e.Reamers f.Cutter EM
g.Taper EM
h. Coniccal and Facet Drills
i.Rock Drills j.Burnishing Drills
k.Centre Drills. 1.E-form Drills

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Type of mill cutters in 2D drawing

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End mill
These types of milling cutters have the cutting teeth on the both sides.
We use end mill more in the vertical milling processes. High speed steel
or the cemented carbide are used to create end mills. High speed steel is
also called as HS or HSS. The high speed steel doesn’t loose its hardness
when the temperature increases. Hence, due to better hardness the high
speed steel is used to make end mills. The end mills are mostly used in
plunging, tracer milling, face milling, etc. Torus cutters, etc. are the
different cutters which are involved in the term end mill.

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Roughing end mill
Roughing end mills quickly remove large amounts of material. This kind
of end mill utilizes a wavy tooth form cut on the periphery. These wavy
teeth act as many successive cutting edges producing many small chips.
This results in a relatively rough surface finish, but the swarf takes the
form of short thin sections and is more manageable than a thicker more
ribbon-like section, resulting in smaller chips that are easier to clear.
During cutting, multiple teeth are in simultaneous contact with the
workpiece, reducing chatter and vibration. Rapid stock removal with
heavy milling cuts is sometimes called hogging. Roughing end mills are
also sometimes known as "rippa" or "ripper" cutters.

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Ball nose
Ball nose cutters or ball end mills (lower row in image) are similar to slot drills,
but the end of the cutters are hemispherical. They are ideal for machining 3-
dimensional contoured shapes in machining centres, for example in moulds and
dies. They are sometimes called ball mills in shop-floor slang, despite the fact that
that term also has another meaning. They are also used to add a radius between
perpendicular faces to reduce stress concentrations.
A bull nose cutter mills a slot with a corner radius, intermediate between an end
mill and ball cutter; for example, it may be a 20 mm diameter cutter with a 2 mm
radius corner. The silhouette is essentially a rectangle with its corners truncated
(by either a chamfer or radius).

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Side-and-face cutter
The side-and-face cutter is designed with cutting teeth on its side as

well as its circumference. They are made in varying diameters and
widths depending on the application. The teeth on the side allow
the cutter to make unbalanced cuts (cutting on one side only)
without deflecting the cutter as would happen with a slitting saw or
slot cutter (no side teeth).
Cutters of this form factor were the earliest milling cutters
developed. From the 1810s to at least the 1880s they were the most
common form of milling cutter, whereas today that distinction
probably goes to end mills. Traditionally, HSS side and face cutters
are used to mill slots and groove

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Thread mill
Main article: Threading (manufacturing) Thread milling
A diagram of a solid single-form thread cutting tool
Whereas a hob engages the work much as a mating gear would (and cuts the
blank progressively until it reaches final shape), a thread milling cutter
A much
operates solid multiple-form thread
like an endmill, millingaround
traveling cutter. the work in a helical
interpolation

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Shell mill
A face mill shell. The rectangular cutout

area on the back side is the pocket that
engages the lugs/tangs of the arbor.
A shell mill is any of various milling cutters (typically a face mill or

endmill) whose construction takes a modular form, with the shank
(arbor) made separately from the body of the cutter, which is called a
"shell" and attaches to the shank/arbor via any of several standardized
joining methods.

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Face mill
A face mill is a cutter designed for facing as opposed to e.g., creating a

pocket (end mills). The cutting edges of face mills are always located along
its sides. As such it must always cut in a horizontal direction at a given
depth coming from outside the stock. Multiple teeth distribute the chip
load, and since the teeth are normally disposable carbide inserts, this
combination allows for very large and efficient face milling

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COMPONENT ANALYSIS

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Solid carbide Tools applications
Carbide is more expensive per unit than other typical tool materials, and it is
more brittle, making it susceptible to chipping and breaking.
This category contains a countless number of applications, but can be split into
three main areas:
• Engineered components
• Some key areas where cemented carbide components are used:
• Tools and tool blanks
• Canning tools for deep drawing of two-piece cans Rotary cutters for high-
speed cutting of artificial fibers
• Metal forming tools for wire drawing and stamping applications Rings and
bushings typically for bump and seal applications
• Woodworking, e.g., for sawing and planing applications
• Pump pistons for high-performance pumps (e.g., in nuclear installations) •
Nozzles, e.g., high-performance nozzles for oil drilling applications Roof and
tail tools and components for high wear resistance
• Balls for ball bearings and ballpoint pens
• Wear parts
•Automotive components

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How to Production?
Production is the process of making or manufacturing goods and products
from raw materials or components. In other words, production takes inputs
and uses them to create an output which is fit for consumption – a good or
product which has value to an end-user or customer.
1.BLANK PROFILE NOMENCLATURE

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1.Precision-ground
Excellent accuracy of dimension and form as well as maximum surface
quality are the basis for successful production of these milling cutter blanks
2.Economical and high-performing
Our unique DualBlank manufacturing technology combines performance
capacity of a premium grade in the cutting edge area with the cost-
effectiveness of a recycled grade on the shank.
3.Comprehensive programme available in stock
In addition to DIN dimensions 6527 K and L, we offer high-precision semi-
finished products in a variety of lengths, executions and grades. Our stock
programme for cut-to-lengths has been newly extended with more than 13
dimensions in inch sizes.
Our unique DualBlank manufacturing technology combines performance

capacity of a premium grade in the cutting edge area with the cost-
effectiveness of a recycled grade on the shank.

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Finish
DualBlank:
Our unique DualBlank manufacturing technology combines
performance capacity of a premium grade in the cutting edge area with
the cost-effectiveness of a recycled grade on the shank.
a. Milling blanks cut to length according to DIN 6527 K&L

b. Extra-long cut-to-lengths in a variety of lengths
c. Chamfer on one end
d. Mirror-polished to tolerance h6 or h5
e. Internal coolant supply
1 radial coolant exit holes
2 radial coolant exit holes
F. Weldon shank
G. Metric and inch dimensions
H. Diameter: 3 mm to 25 mm

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2.END MILL FIUTE PROFILE NOMENCLATURE

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Flutes. Flutes are the easiest part of the end mill to recognize. These
are the deep spiraled grooves in the tool that allow for chip formation
and evacuation. Simply put, flutes are the part of the anatomy that
allows the end mill to cut on its edge.
Nomber of fluting
a.Square EM(2FL 3FL & 4FL)
b.Ballnose EM(2FL & 4FL)
c.Corner radius EM(2FL & 4FL)
a.Square EM(2FL 3FL & 4FL)

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3.END MILLS: Outside diameter relieving nomenclature and its

types

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4. SQUARE END MILLS: End operation geometry and

its types.
Cutting operation
End mills do not have cutting teeth across all of the end, but have a ‘dead’
area in the centre, and thus can only be used for milling using the side of the
cutter and the outer periphery of the ending end
While end mills have traditionally had four cutting flutes, recently
cutters with three flutes and higher helix angles have been introduced.
These have one cutting edge ground right to the centre, and thus can be
used to drill directly into the workpiece when creating a recess. Cutters
designed for roughing work may have chip-breaking grooves in the
flutes, while cutters used for finishing work will have continuous flutes. A
high helix angle provides lower loads per cutting edge and a higher
degree of accuracy and finish on deep cuts.

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USING A MILL CUTTIN TOLLS

Chip formation
Although there are many different types of milling cutter, understanding chip
formation is fundamental to the use of any of them. As the milling cutter rotates,
the material to be cut is fed into it, and each tooth of the cutter cuts away a small
chip of material. Achieving the correct size of chip is of critical importance. The size
of this chip depends on several variables.
Surface cutting speed (Vc)
This is the speed at which each tooth cuts through the material as the tool spins.
This is measured either in metres per minute in metric countries, or surface feet per
minute (SFM) in America. Typical values for cutting speed are 10m/min to 60m/min
for some steels, and 100m/min and 600m/min for aluminum. This should not be
confused with the feed rate. This value is also known as "tangential velocity."
Spindle speed (S)
This is the rotation speed of the tool, and is measured in revolutions per minute
(rpm). Typical values are from hundreds of rpm, up to tens of thousands of rpm.
Diameter of the tool (D)
Number of teeth (z)
Feed per tooth (Fz)
This is the distance the material is fed into the cutter as each tooth rotates. This
value is the size of the deepest cut the tooth will make.Typical values could be 0.1
mm/tooth or 1 mm/tooth
Feed rate (F)
This is the speed at which the material is fed into the cutter. Typical values are from
20 mm/min to 5000 mm/min.
Depth of cut
This is how deep the tool is under the surface of the material being cut (not shown
on the diagram). This will be the height of the chip produced. Typically, the depth of
cut will be less than or equal to the diameter of the cutting tool

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DRILLS

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INSPECTION
The quality of the any product can be measure in
terms of standard items of drawing. This process is called inspection it
gives the measurement of a product or its quality in terms of prescribed
standards. Inspection compares material, product of performances with
established standards it also reflects on the quality of each part after
each process is completed. This is called stage inspection. Inspection of
core & cavity should be carried out thoroughly because any slight
dimensioned variation affects the accuracy of component.
The various parts of the tool were inspected after each
stage of manufacture using common shop floor measuring instruments
like micro meter,vernier caliper, slip gauge, digital vernier,height master
etc.
ADVANTEGES OF FLOOR INSPECTION.

1. It can helps to removing the defects while doing the work.
2. It caught in time prevent spoilage of large amount of work.
3. It saves the wastage of time.
4. It reduces the labor cost.
5. Reduction work in process is possible.

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COMPONENT INSPECTION

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QUALITY
Quality means degree of perfection.

Quality department is generally divided into two groups namely
Quality Control
Quality Assurance
Quality
Dept
Quality Quality
Control Assurance
Quality Control:
Quality of a product depends upon the application of materials,
men, machines and manufacturing conditions. The systematic
control of these factors is called Quality Control.
Quality Assurance:
The planned & systematic actions necessary to provide adequate
confidence to the Customers that a product will satisfy their
requirements.
In simple words - Assuring that the product supplied by us is
PERFECT.
INSPECTION
Inspection plays an important role in tool making of manufacturing
of any part. It seems that the manufactured component or part will have
it own importance in a particular field in order to determine the fitness
of anything made. Man has always used inspection.

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But industrial inspection is recent origin has scientific approach
behind. It came into existence because of mass production, which
involve interchangeability of parts. Lastly inspections lead to
improvement in raw material manufacturing due to demands of high
accuracy and precision. Inspection has also introduced spirit of
competition and led to production of quality products.
PURPOSE OF INSPECTION:
To collect information regarding the performance of the product with
established standards.
To sort out poor quality manufactured products and
thus maintain the standard.
To establish and increase the reputation by protecting
consumers from receiving bad products.
IMPORTANCE OF INSPECTION:
Inspection traces defects in raw material, flaws in process, and

those arising in production due to defective machinery or process.
Inspection avoids further work on non-finish parts already
detected as spoiled.
Inspection rectifies any changes or dimensional variation in the
profile of the part.
•
INSPECTION MEYHODS:
Inspection can be categorized in respect to the method used.
1. Measurement: -
This involves determination of the numerical value of an instrument,
venire caliper, and micrometer
CMM, VMS, HIGHT MASTER, INSPECTIONS FIXTURES &
GAUGES
etc.
2. Functional checking: -
It involves testing, the function of a product practically by
assembling it with the mating part in order to clarify whether the
guiding and locking areas are moulded properly for its efficient
function.

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3.Visual inspection: -
This method involves the use of the human eye to judge the quality
and aestheticism of a product.
Types of inspection:
Tool Inspection.
First Piece Inspection.
Working Inspection
Sample Inspection.
Operation Inspection.
Final Inspection.
Key operation Inspection.
Functional Inspection.
Floor or Patrol Inspection.
Measuring instrumentsused in the tool are dial
vernier, micrometer, dial indicator etc.
The part should also be inspected in assembly to check whether
the fitting portion is acceptable and alignment of the part with its
mating part.
Inspection should be good enough to point out whether the problem is
with the actual part or in the mating part, if any.
METHODS OF INSPECTION
There are mainly three types of inspection.
1. Floor inspection
2. Centralized inspection
3. Combined method of inspection
In floor inspection, the inspector walks around
on the shop floor and inspects the jobs
In centralized type of inspection, all the jobs to be inspected are
moved to a separate room for inspection. In combined method of
inspection, shop floor and centralized inspection are combined
together.

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COMPONENT INSPECTION
The quality of the any product can be measure in terms of
standard items of drawing. This process is called inspection it gives the
measurement of a product or its quality in terms of prescribed
standards. Inspection compares material, product of performances
with established standards it also reflects on the quality of each part
after each process is completed. This is called stage inspection.
Inspections of product are mainly inspected after hardening. Should be
carried out thoroughly because any slight dimensioned variation affects
the accuracy of component.
The method of inspection used in this product was room
inspection or centralized inspection. The various samples of the product
were inspected using precision devices and also inspected by common
measuring instruments like microscope, micrometer, vernier caliper, slip
gauge, digital vernier, height master, profile projector, cmm, stander
gauges & fixtures etc.
Stages of Inspection in Indo-MIM

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List of Instruments and Equipment's to be used for inspection.
Equipments:
➤Profile Projector
➤Tool Maker Microscope
➤Weldon Geometry
➤Helicheck Basic 3
➤Visual Inspection System
Instrument's:
➤Digital Outside Micrometer:LC-0.001mm
➤Digital Spline Micrometer:LC-0.001mm
➤Analog Outside Micrometer: LC-0.01mm,0.001mm
➤Analog Point Micrometer:LC-0.01mm
➤Digital Vernier Caliper:LC-0.01mm Analog Vernier Caliper: LC-0.02mm
➤Height Gauge:LC-0.01mm
➤Surface roughness Tester:LC-0.001 micron Ra
➤Runout measuring Instruments:0.001mm,0.0001"
➤Depth Gauge:LC-0.01mm

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PROFILE PROJECTOR :
Profile projectors (optical comparators) are a type of optical measuring

instrument. The measurement principle is similar to that of optical
microscopes. The target is placed on the stage, and a light is shined on the
target from underneath. This causes the target's profile, or shadow, to be
projected on the screen.
APPLICATION :
Profile projector is used to check the linear dimensions, angular
dimensions, diameter, distance, radius & profile of the component by
matching with profile chart etc..

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Profile Projector Parts
A:projection screen
B:Projection lens
C:Movable stage
D:Stage movement handles (X and Y handles)
How to Use (Basic)

A scale is applied to the image projected enlarged on the screen to
measure the dimensions. Alternatively, you can use the XY stage together
and measure the dimensions from the amount of movement.
A profile projector with a computerised calculation function, you can
obtain various measurement results such as width, diameter, and angle
by taking measurement points while moving the stage.

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How to Measure a Length/Width
Place the object to be measured on the screen and adjust the height of the table to
focus.
Next, align the orientation of the side you want to measure on the projected image
with the orientation of the screen reference line, and adjust the value of the XY
stage to 0.
Next, move the stage using the stage movement handle and align the other side of
the projected image to be measured with the screen reference line.
At this time, the movement amount of the stage is displayed in each of the X and Y
directions, so this value becomes the measured value. In the case of simple
measurement in only one direction, the amount of movement in only the X or Y
direction is used.
How to Measure a Radius/Diameter
Place the object to be measured on the screen and adjust the height of the table to
focus.
Next, align the centre point of the circle on the projected image with the point
where the screen reference line is public.
In the case of radius, take 0 points here and move the stage to check the movement
amount at the point where the edge of the circle was at the centre of the stage. In
case of diameter, move the stage once from here to the edge of the circle, take 0
point, and move to the opposite edge to check the amount of movement. In either
case, it is common to measure in four directions in a cross shape.
It is also possible to measure by applying a concentrically graduated sheet called a
"chart" to the screen.
In the case of a profile projector with a calculation function, the diameter and
radius are automatically calculated by taking three measurement points at the edge
of the circle.
How to Measure Angles
There are several ways to measure the angle.
A method of checking the amount of rotation of the stage by rotating the stage in
the θ direction by aligning the straight line of the projected image with the
reference line of the screen.
There is a method of checking by putting a sheet called "chart" with fine scale like
a protractor on the screen.

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Measuring Microscopes (Toolmakers Microscopes)

Overview
Measuring microscopes combine an optical microscope with a table capable
of precise movement to measure targets. As with optical comparators, a
telecentric optical system is used to enable accurate measurements.
Measurements can be performed in a non-contact manner, so there is no risk
of damaging the target.
Different types of measuring microscopes are available to match different
applications. Examples include toolmakers microscopes, factory-use
measuring microscopes, and general-purpose measuring microscopes. The
characteristics of these microscopes are outlined below.
Toolmakers microscopes: Originally used to measure tools, these were the first
measuring microscopes.
Factory-use measuring microscopes: These microscopes are suited to the
measurement of small, processed parts and similar items.
General-purpose measuring microscopes: These microscopes support .a wider
range of applications than toolmakers microscopes and can measure large
objects.

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Construction and Applications of Measuring Microscopes

A:Measured data display
B:Objective lens
C:Movable stage
D:Stage movement handles (X and Y handles)How to Use a Measuring

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How to Use a Measuring Microscope

Place the target on the stage.
As with general-purpose optical microscopes, subject the target to
transmitted light or reflected light, and then align the edge of the shadow
with the reference lines to perform measurement. Use different lighting
(such as backlighting and coaxial illumination) depending on the target.
The measured values can then be output as various types of CAD data.
Handling Precautions
Just as with general-purpose microscopes, measuring microscopes must
be used in an environment free of dust. The stand on which the
measuring microscope is installed must also be level and free of
oscillations.
After use, cover the measuring microscope to prevent dust from adhering
to it.
The calibration interval for measuring microscopes is 1 to 3 years.
The Latest Measuring Microscopes
Recent models of measuring microscopes are able to instantly measure
dimensions without XY stage movement or focusing, enabling the
measurement of many objects in a short amount of time.

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HELICHECK 3D
Basic Data
The HELICHECK 3D measuring machine generates 3D models of tools and
production parts. One completely new technology is the ability to scan tools
and comparing the scan to a target model from the customer's CAD/CAM
system. It is the easiest and fastest way to scan a tool and then analyze the
virtual image of the tool or compare it to the target model. Take advantage
of this new tool digitization technology.
Features
With the 3D Scan procedure, tools and workpieces can be scanned very
quickly and easily , with their entire geometry registered.
Solid granite base
A solid granite basis has the weight to deliver precision and accuracy. The
granite base dampens vibrations and is thermally stable. These are the
prerequisites for very high measurement accuracy and reliable measurement
results.
ISO 50 Spindle
The high-precision ISO 50 spindle with automatic clamping mechanism
provides precise and repeat

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Ball roller spindle

High precision ball roller spindles and linear guides
guarantee excellent positioning accuracy, which is a
prerequisite for precision measurement results.
Hardware / Software
Modular adaptor spindle
Rapid-switch adapters can be exchanged quickly and
easily without further setup time. The following quick
change adapters are available: ISO/HSK/Capto/VDI.
Centre holder
For tools that for technical reasons must be produced
between centres, the high concentricity precision must
also be fulfilled during the measurement process.
WALTE

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DIGITAL OUTSIDE MICROMETER
The digital Mitutoyo spline micrometer is ideal for measuring minor

indents, slots, spline shafts and keyways on workpieces. The anvil and
spindle each have reduced diameters to better measure internal features
with high accuracy.
This Digimatic Spline Micrometer makes it easy for you to measure

grooves and shaped parts. It offers you the following
benefits:Outstanding accuracy and ...
Scale: Thimble and sleeve satin chrome finish, ø18 mm
Power supply: 1 battery SR-44
Display: LCD, character height 7.5 mm

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RUNOUT MEASURINGMEASURING FIXTURE

Automated inspection systems for fast, high-precision runout
measurements. Concentricity. Eccentricity. Circular Runout. Radial
and Axial Runout. Circular Flatness. Circular Parallelism. Measure
Journal Roundness.
INTRODUCTION
The fixture is a special tool for holding a work piece in proper position
during manufacturing operation. For supporting and clamping the work
piece, device is provided. Frequent checking, positioning, individual
marking and non- uniform quality in manufacturing process are
eliminated by fixture. This increase productivity and reduce operation
time. Fixture is widely used in the industry practical production because
of feature and advantages. To locate and immobilize work pieces for
machining, inspection, assembly and other operations
INSPECTION FIXTURES-Used to ensure that the work piece meets a

standard for size and shape the main requirement of an inspection fixture
is accuracy. Inspection fixture should contain only those elements needed
to check the specified sizes.

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HANDLING OF INSTRUMENTS AND EQUIPMENT'S.
➤ All instruments and Equipment's are too

precision and highly valuable.
➤ Without knowledge of the Instruments and
Equipment's do not use.
➤ Please get the awareness from the trainer
fully and get the training to handle and using
of Equipment's and Instruments.
➤ Keep the Instruments Proper place when
completion of your work.
➤If any accidently miss handling of the
Instruments and Equipment's, Inform the same
to concern person without fail.
➤If any doubt about the Instruments are
Equipment's. Kindly go through the user
Manual.
➤For HANDLING OF TOOLS please refer the no
touch policy

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RAW MATERIAL SELECTION

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This company useing Raw material

Solid carbide and High-speed steel (HSS or HS)
1.SOLID CARBIDE
a. Solid carbide is a chemical compound containing equal parts of

tungsten and carbon atoms. In its most basic form, tungsten carbide is
a fine gray powder, but it can be pressed and formed into shapes
Formula: WC
Density: 15.63 g/cm³
Melting point: 2,870 °C
Molar mass: 195.86 g/mol
Appearance: Grey-black lustrous solid
Thermal conductivity: 110 W/(m·K)

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The material is usually called cemented carbide, solid carbide, hardmetal or

tungsten-carbide cobalt. It is a metal matrix composite, where tungsten carbide
particles are the aggregate, and metallic cobalt serves as the matrix.
Other cations: Molybdenum carbide; Titanium carbide; Silicon carbide
Other anions: Tungsten boride; Tungsten nitride
Boiling point: 6,000 °C (10,830 °F; 6,270 K); at 760 mmHg
Lattice constant: a = 2.906 Å, c = 2.837 Åα = 90°, β = 90°, γ = 120°
Applications of tungsten carbide

a. Replaceable chip for cutting tools. The chip used for turning or rotary
cutting.
b. Drill for printed circuit board. An extremely small diameter drill used for
drilling on semiconductor substrates.
c. End mill. A cutting tool used to widen the hole by grinding off with the
blade on the side.
Drill.

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Replaceable chip for cutting tools

The chip used for turning or rotary cutting
Drill for printed circuit board
An extremely small diameter drill used for drilling on
semiconductor substrates
End mill
A cutting tool used to widen the hole by grinding off with the
blade on the side
Drill
A cutting tool used for drilling holes

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Abrasion resistant tools
Mold
A metallic mold used to make material shaped
Die
A tool used for wire drawing
Roll
A tool used for rolling, molding, polishing materials
Nozzle
A tool used to inject fluids

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Characteristics of tungsten carbide
1. High hardness
The Mohs’ hardness of tungsten carbide is “9.” It boasts

a level of hardness second to diamond.
2. High strength at high temperature

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3.High resistance to corrosion
Tungsten carbide is an extremely stable substance, and it does not

oxidize at normal temperatures in air. In addition, it is not likely to
form a solid solution with various elements, and keeps stable
characteristics even in severe environments.
.Resistance to oxidation
Oxidation occurs at approximately 300 ℃ and reaction occurs rapidly
at approximately 700℃ to form an oxide (WO ₃) when its powder is
heated in an oxygen-containing atmosphere.
.Chemical resistance
Although it does not dissolve in water, hydrochloric acid or sulfuric
acid, it dissolves in nitic acid.
.Reactivity
Reacts with chlorine at 400℃ or higher.
Reacts with fluorine at 18℃.

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2.HIGH SPEED STEEL
b. High-speed steel (HSS or HS) is a subset of tool steels, commonly used

as cutting tool material. It is often used in power-saw blades and drill bits.
It is superior to the older high-carbon steel tools used extensively through
the 1940s in that it can withstand higher temperatures without losing its
temper (hardness).

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High speed steels are alloys that gain their properties from a variety of
alloying metals added to carbon steel, typically including tungsten and
molybdenum, or a combination of the two, often with other alloys as well.[8]
They belong to the Fe–C–X multi-component alloy system where X
represents chromium, tungsten, molybdenum, vanadium, or cobalt.
Generally, the X component is present in excess of 7%, along with more
than 0.60% carbon.
In the unified numbering system (UNS), tungsten-type grades (e.g. T1, T15)
are assigned numbers in the T120xx series, while molybdenum (e.g. M2,
M48) and intermediate types are T113xx. ASTM standards recognize 7
tungsten types and 17 molybdenum types.[9]
The addition of about 10% of tungsten and molybdenum in total maximises
efficiently the hardness and toughness of high speed steels and maintains
those properties at the high temperatures generated when cutting metals.

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Molybdenum High Speed Steels (HSS)
Combining molybdenum, tungsten and chromium steel creates several alloys
commonly called "HSS", measuring 63–65 Rockwell "C" hardness.
M1
M1 lacks some of the red-hardness properties of M2, but is less susceptible to
shock and will flex more.
M2
M2 is the "standard" and most widely used industrial HSS. It has small and evenly
distributed carbides giving high wear resistance, though its decarburization
sensitivity is a little bit high. After heat treatment, its hardness is the same as T1,
but its bending strength can reach 4700 MPa, and its toughness and thermo-
plasticity are higher than T1 by 50%. It is usually used to manufacture a variety of
tools, such as drill bits, taps and reamers. 1.3343 is the equivalent numeric
designation for M2 material identified in ISO 4957.
M7
M7 is used for making heavier construction drills where flexibility and extended
drill life are equally important.
M50
M50 does not have the red-hardness of other grades of tungsten HSS, but is very
good for drills where breakage is a problem due to flexing the drill. Generally
favored for hardware stores and contractor use. It is also used in high-
temperature ball bearings. These steels are obtained by alloying tungsten,
chromium, vanadium, cobalt and molybdenum with steel.
Cobalt High Speed Steels (HSS)
The addition of cobalt increases heat resistance, and can give a Rockwell
hardness up to 70 Min.[12]
M35
M35 is similar to M2, but with 5% cobalt added. M35 is also known as Cobalt
Steel, HSSE or HSS-E. It will cut faster and last longer than M2.[13]
M42
M42 is a molybdenum-series high-speed steel alloy with an additional 8% cobalt.
[12] It is widely used in metal manufacturing industries because of its superior
red-hardness as compared to more conventional high-speed

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Applications
The main use of high-speed steels continues to be in the manufacture of

various cutting tools: drills, taps, milling cutters, tool bits, hobbing (gear)
cutters, saw blades, planer and jointer blades, router bits, etc., although usage
for punches and dies is increasing.
High speed steels also found a market in fine hand tools where their relatively
good toughness at high hardness, coupled with high abrasion resistance, made
them suitable for low speed applications requiring a durable keen (sharp)
edge, such as files, chisels, hand plane blades, and damascus kitchen knives
and pocket knives.[citation needed]
High speed steel tools are the most popular for use in woodturning, as the
speed of movement of the work past the edge is relatively high for handheld
tools, and HSS holds its edge far longer than high carbon steel tools can.
[citation needed] High speed steel is used for cast iron cutting as well in CNC
machines.

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TOOL DESIGN ANALYSIS

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1. The customer gives the part drawing. Based on the requirement

i.e. the quantity, the number of cavities is decided.
1. The green part size is determined by considering the shrinkage due to
sintering.
2. The component arrangement in the mould is decided i.e. the cavity
placing.
3. The shank and pip in the component, which are of circular profile,
are offset requiring a stepped parting surface.
4. The undercut in the catch, which is located in the main profile area
necessitates the side core slide.
5. The hole, which is in-line with the pip, can only be achieved by
accommodating the side core pin. This pin has to be in compound
angle.
6. Since the side core pin is at the compound angle the axis of the pin
comes inside the parting surface. Which means the core pin should be
square or rectangular at the parting surface.
7. The profile area in the core pin has to be made off-centered as the pip
projects out.
8. The serration in the backside of the component has no negative angle.
The profile can be directly sinked into core & cavity.
9. Then the type of ejection is decided. In this mould pin ejection is used.
4 ejector pins are used in the profile area.
10. The cavity placing is then decided. I.e. placement of cavity from hot-
tip i.e. the injection point. Two cavities are placed symmetrically at a
distance of 40 mm from center.

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1. The runner type, gate position, type and size are determined. The
type of runner used in this mould is round and the type of gate used is
edge gate.
2. The size of core and cavity is determined considering the slides and
gibs.
3. The suitable mould base is selected based upon the core plate and also
considering the ejection stroke necessary for complete ejection The
serration in the backside of the component has no negative angle. The
profile can be directly sinked into core & cavity.
4. Then the type of ejection is decided. In this mould pin ejection is
used. 4 ejector pins are used in the profile area.
5. The cavity placing is then decided. I.e. placement of cavity from hot-
tip i.e. the injection point. Two cavities are placed symmetrically at a
distance of 40 mm from center.
6. The runner type, gate position ,type and size are determined. The
type of runner used in this mould is round and the type of gate used is
edge gate.
7. The size of core and cavity is determined considering the slides and
gibs.
8. The suitable mould base is selected based upon the core of the
component.
2 Clamping hole location for core cavity and gibs

0 are
determined
.1. Effective cooling hole circuit is decided.
2. Finger cam positioning and length is determined depending upon the
movement needed for the component to be fully released from the
slide.
3. Then size and dimensions of the various elements are determined i.e.
4. Core, cavity, slides, gibs, finger cams, wedges, ejector pins, etc.

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Part design, requirements, quantity ordered, no of pieces /time
No of cavities
Selection of injection molding machine
Type of mold
Two plate mould OR three plate mould
Placement of cavities
Star arrangement symmetrical in-line
Type of gating
Conventional pin-point sub-marine

flash tab disc diaphragm
Type of ejection
Pins stripper rings/plate air slides side-cores
Type of venting
Parting line core inserts

ejector pins plates porous metal
pins
Mold materials
Mold base inserts or mold plates cores
Anticipated shrinkage
Part design gating processing conditions
Design

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MIM-DESIGN TOLARANCE

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CUTTING TOOLS
Read the design

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CUTTING TOOLS

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CUTTING TOOLS
First operation Flute

4 Asymmetrical Divided Flutes & Variable Helix Angle for Reduced
Vibrations When Milling. VariMill™ Extreme™ Is Made To Perform Well
in a Broad Range of Work Piece Materials. Super Versatile.

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Setting

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Second operation outside grinding
Grinding mill stable performance, good grinding effect, professional

mill manufacturer. Leading technology, factory direct sales, wide range
of applications, Metso Outotec Premier™ mills and Select™ mills are
built to eliminate unplanned downtime. No matter your application or
needs, we have a solution to help optimize your operation.

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Remark

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Setting

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END OPERATION GEOMETRY
Cutting operation. End mills do not have cutting teeth across all of
the end, but have a 'dead' area in the centre, and thus can only be
used for milling using

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CUTTING TOOLS

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All operation end inspection the full tool

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ESTIMATION AND COSTING

ESTIMATION : It is an art of finding the cost of the product before it
is going to be manufactured. It can also be defined
as finding the probable cost of the product by
assuming the cost and expenses which are going
to occur in different sections and process.
Estimation requires highly skilled technical
knowledge about manufacturing methods and
operating time
IMPORTANCE OF ESTIMATING:
In all organizations, before starting actual production or filling up
tenders, estimation is done. Therefore accurate estimating is very
necessary to compete in the market and to be sure whether
manufacture of a particular component will be profitable or not.
Both over and under estimating are dangerous. Over-estimating leads
to increase the cost and hence tenders may not get suitable
response. Under estimating may lead to losses to the concern.
Hence accurate is very essential and therefore, staff of the
estimating department must be well qualified, experienced and
trained in this profession.
AIMS OF ESTIMATION
1. To help the factory owner in deciding the manufacturing and
selling policies.
2. To help in filling up tender enquiries.
3. To decide about the amount of overheads, which helps in
comparing and checking the actual overheads of the factory.
4. To decide about the wage rates of the workers after making
“Time Study”.

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5. It helps to decide whether a particular material should be
purchased from the market or to be manufactured.
Profit Selling
Price
S=P+T
Administra Total
tion and cost
Selling T=F+A
expenses
Overhead (A)
Manufacturi
ng or
Factory cost
Prime cost F=W+M+E
Direct labour =(W+M)
Direct material
Since estimation of labor cost machining cost & raw material cost is a laborious
process and calculation, only conclusion part of the calculation is shown.
MATERIAL COST:
Cor : Rs
bet : 80/kg
Case : Rs
hardened : 90/kg
Copper : Rs 50/kg
Orvar Rs 500/kg
Supreme Rs 110/kg
COSTING: Costing is the technique or process of ascertaining costs. It is the
determination of the actual cost of the product after adding different
expenses incurred in various departments. It not only helps us to know the
actual cost of the product but also helps to know what they should have
costed. It helps us to know where losses are occurring .

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ELEMENTS OF COSTING:
Material cost
1.
2. Labour cost
3. Expenses (overheads)
MATERIAL COST:
Direct material cost: Example: Raw materials.
Indirect material cost: Example: coolants, tools, machines,
cotton waste.
LABOUR COST
Direct labour: The workers, who actually work or process different
materials manually or with the aid of machines are known as Direct
Labour. The nature of their duties is such that their wages can be
directly charged to the job, which they are manufacturing.
Indirect labour: Any other labour, who helps the productive
labour in performing their duties, is known as “Indirect Labour”.
Example: Foreman, Supervisors, and Inspectors.
EXPENSES
In each factory there are several other expenditures, such as cost
of advertisement, building rent, depreciation charges of plant and
factory building, cost of packing, cost of transportation, salaries and
commission to sales men, etc. All these expenditures are known as
“Expenses”.
Direct Expenses: Example: cost of special jigs and fixtures,
special purpose machine, etc.

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PRIME COST = Raw material cost + Machining cost +
Assembly charges.
Where:
Safety = 25% of prime cost.
Overheads and administrative expenses = 20% of prime cost
Standard items = 10% of the prime cost

Design charges = 20% of total cost
Profit = 30% of total cost.
COSTING:
The technique and process of ascertaining cost is known as costing.
Costing is classifying and recording the appropriate allocation of
expenditurefor the determination of the cost of products of
services.
ELEMENTS OF COSTING:
For easy and accurate calculation the total of a product to be
manufactured can be divided into three main elements. They are:
MATERIALS:
A) Direct Material B) Indirect Material.
1. LABOUR:
A) Direct Labour B) Indirect Labour.
2. EXPENSES:
A) Direct Expenses B) Indirect Expenses.

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Indirect Expenses: These are also known as overhead charges. On
costs, on burden, in-direct charges, secondary cost or supplementary
cost are also known as indirect expenses.
OVERHEADS
Overheads can be defined as, “Total cost of indirect materials,
wages and expenses”. It can also be defined as, “the operating costs of a
business enterprise which cannot be traced directly to a particular unit of
output”.
1. Fixed overheads
2. Variable overheads
Costing is done by considering the following points:
3. Prime cost.
4. Factory cost.
5. Office cost.
6. Total cost.
THE TOTAL CAN BE WELL UNDERSTOOD BY THE
BELOW TABLE
SELLING PRICE E= P+T

PROCEDURE OF ESTIMATION TOOL COST
Total tool cost:
TOTAL COST = Prime cost + Safety + Overheads
+ Cost of standard items + Design charges + Try
out + Profit.

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OPERATION S COST

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TOTAL COST: RS=46,350
DESIGN COST RS = 11,587(25% OF THE TOTAL

COST)
PROFIT RS = 9,270 (20% OF THE TOTAL COST)
TOTAL RS=67, 207 TOOL COST

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CONCLUSION
This project report on ‘cutting tools, this gives the general idea of
tool making by explaining the various
aspects, from designing process to machining.
This project report is an idea and acts as a reference
guide in the Tool making & Tool Design. It tells us the methodical
way of manufacturing a tool and how to overcome some problems
in cutting tools process.
As a whole this project has helped in improving our
overall skills as a Tool maker and also helped us in presenting our
views, regarding this particular trade and project

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SAFETY PRECAUTIONS

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GENERAL SAFETY PRECAUTIONS

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PERSONAL SAFETY
PRECAUTIONS:

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PROJECT REPORT 2021-2022

KIADB INDUSTRAIAL ARE

MANUFACTURING OF CUTTING TOOLS

GOVT. TOOL ROOM & TRAINING CENTRE

KIADB INDUSTRAIAL ARE

(A Scientific & Industrial Research Organization Recognized by Government of India)

YG CUTTIN TOOLS -1 INDIA Pvt Ltd .

KIADB INDUSTRIAL ARES

This to certify that Mr RAKESH V R Reg.No.1260231 of IInd BATCH

PROJECT GUIDE PRINCIPAL

GOVT. TOOL ROOM & TRAINING CENTRE

PROJECT REPORT EVALUATION

NAME : RAKESH BATCH :2

GOVT. TOOL ROOM & TRAINING CENTRE

I’m also greatfull to our Mr. THIPPESWAMY . C Manager/Unit Head

GOVT. TOOL ROOM & TRAINING CENTRE

Signature of the candidate

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Government Tool Room and Training Centre (GTTC) was established in

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GT&TC, GOWRIBIDANUR centre was started in 2017 to cater to the

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Hi-Tech Components for

Training - Long Term

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Training - Short Term

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"YG-1will keep develop ing further more innovative itams

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YG-1 Mission, Vision & Core Value

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YG-1, FULL RANGE CUTTING TOOL SUPPLIER

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Jul 2000 Selected as the company with outstanding

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